Nano-enhanced wound dressing

ABSTRACT

The present disclosure relates to a dermal drug delivery platform comprising: a primary wound dressing comprising three-dimensional polymer protuberances that extend upward from the dressing surface to engage the wound. The protuberances comprise at least one biocompatible and/or biodegradable polymer and medicinal nanoparticles. In one embodiment, the medicinal nanoparticles may be metallic and provide surface-area-enhanced galvanic action to drive medicinal ions into the wound bed. Various methods of making the disclosed dermal drug delivery platform, as well as three-dimensional methods of treating a wound using the platform are also disclosed.

This application claims the benefit of priority under 35 USC 119(e) toApplication No.: 61/956,479, filed on Jun. 10, 2013, which is hereinincorporated by reference in its entirety.

BACKGROUND

Wound dressings, or simply dressings, are quantitatively characterizedby a number of different parameters such as their: geometry (e.g., size,shape, number of layers and thickness of each layer), materialcomposition (e.g., of each layer, including the use of polymer coatings,etc), conformality (e.g., their ability to conform to the topography ofthe skin surface), mechanical properties (e.g., tensile strength,elasticity), surface properties (e.g., flat, dimpled, textured, etc),moisture management (e.g., wicking, wetting, moisture penetration,hydrophilic, hydrophobic, evaporation, etc), mode of sterilization,anti-microbial, anti-fungal and/or anti-biotic properties, airpermeation, vapor permeation, vacuum compatibility, hypoallergenicproperties, textile properties (e.g., thread count, warp, weft, weave,cutting properties (edge fraying), etc), infused medicinal content (ifany), color, ergonomics, mean time to replacement and the variousadhesion mechanisms used for holding them in place, among other things.

A long-standing goal of the medical community in general is to selectthese various dressing parameters to minimize the “mean time to woundhealing” (MTWH) for a highly diverse population of patients, with ahighly diverse set of wound conditions, all-the-while adheringstringently to any and all Rules & Regulations imposed by the Food andDrug Administration (FDA), and to implement high-volume manufacturingmethods that would enable inexpensive world-wide accessibility.

Traditionally, dressings were made of gauze pads or bandages made fromnatural and/or synthetic materials wherein wound exudate would beabsorbed by the dressing to keep the wound dry and to help prevent theingress of harmful bacteria. More recently, however, it has been shownthat wounds heal faster and more efficiently when they are kept moist.

It has been known for many years that certain metals possessanti-microbial, anti-bacterial, anti-fungal, anti-biotic and/or othermedicinal properties when introduced into a wound system (see forexample, Von Nageli, “On the Oligodynamic Phenomenon in Living Cells”,Denkschriften der Schweizerischen Naturforschenden Gesellschaft, Vol.33, No. 1, p. 174, 1893 and McKhann, Carlson, and Douglas, “OligodynamicAction of Metallic Elements and of Metal Alloys on Certain Bacterial andViruses”, Pediatrics, Vol. 2, p. 272, 1948). These metals include:silver (Ag), gold (Au), platinum (Pt), palladium (Pd), copper (Cu), andzinc (Zn), among others. Of these, however, silver is perhaps the bestknown.

Anodic silver at low direct currents is known to have inhibitory,anti-bacterial and/or anti-fungal properties. See for example, Berger,(“Antifungal Properties of Electrically Generated Metallic Ions”,Antimicrobial Agents and Chemotherapy, Vol. 10, No. 5, November 1976, p.856) and Spadaro (“Antibacterial Effects of Silver Electrodes with WeakDirect Current”, Antimicrobial Agents and Chemotherapy, Vol. 6, No. 5,November 1974, p. 637).

Additionally descriptive of antimicrobial surfaces comprising two ormore metals in contact with a body electrolyte that produces galvanicaction is U.S. Pat. No. 4,886,505 to Haynes et al. Other patents whichdescribe galvanic cells and galvanic elements, include U.S. Pat. No.5,685,837, Horstmann; and U.S. Pat. No. 6,365,220 to Burrell, which areincorporated by reference herein. However, prior art approaches arelacking in numerous respects. For example, Burrell's approach requiresmultiple evaporations of different metals and subsequent metal etchingtechniques that, more-often-than-not, require the use of highlycorrosive chemicals and/or toxic gas plasmas (such as chlorine and/orfluorine). More importantly, nowhere in Burrell's work does he mentionthe use of metallic anti-microbial nanospheres suspended in an array ofbiodegradable polymer nano and/or micropillars.

U.S. Pat. No. 7,457,667 to Skiba, which is also incorporated byreference, describes a current-producing wound dressing but does notsuggest using micropillars to increase the contact surface area betweenthe wound electrolyte and the galvanic surface. Skiba also fails tomention the important class of biodegradable polymers that can be usedfor a controlled release of the metallic ions. Instead, he refers onlyto “biocompatible binders” that are used in making the inks. Skibadescribes a more traditional surface effect to wound healing. This canbe considered a two-dimensional approach to wound healing because theink described in this reference is in proximal contact with the woundsurface, and is not inserted into a wound, which can be considered athree-dimensional approach to wound healing. For example, in a threedimensional approach to wound healing, protuberances or pillars areactually inserted into the wound for a three dimensional response.

SUMMARY

To the best of applicant's knowledge, nowhere in the prior art hasanyone utilized a wound dressing comprised of patterned biodegradablepolymer protuberances with medicinal particles contained therein, asdescribed herein. Such a construct could and/or should allow for:enhanced galvanic action to push more medicinal ions into the wound bed,extracellular scaffolding with preferential/differential cell growthexhibited thereon, and/or better moisture management, for example.Accordingly, there is a pronounced need for incorporating suchnanoparticle-containing biodegradable polymer protuberances into anano-enhanced wound dressing to facilitate, for example,heretofore-unprecedented rates of wound healing along with possibleother advantages.

Herein, there is disclosed nano-enhanced wound dressings that employnumerous patterned protuberances with multiple medicinal nanoparticlescontained therein to facilitate the healing process when placed intodirect contact with the wound. There is also disclosed wound dressingsas described, that further employ galvanic action to assist in woundhealing. Embodiments described herein include articles, methods ofmaking articles, and methods of using articles.

For example, one embodiment provides a dermal drug delivery platformcomprising: a primary wound dressing comprising three-dimensionalpolymer protuberances that extend upward from the dressing surface toengage the wound, wherein the protuberances comprise at least onebiocompatible and/or biodegradable polymer and medicinal nanoparticles.

In one embodiment, the polymer protuberances have a columnar or pillarshape with a base having a longest dimension ranging from 1 μm to 1000μm, and a cross-section shape that is round, square, rectangular,hexagonal, elliptical, completely general, or combinations thereof.

In another embodiment, the medicinal nanoparticles are metallic and areselected from: silver, gold, copper, zinc, platinum, palladium and/orcombinations thereof.

In another embodiment, the wound comprises an electrolyte, and themetallic nanoparticle-containing polymer protuberances are selected tomaximize a galvanic response between said protuberances and theelectrolyte.

In another embodiment, the medicinal nanoparticles are uniformlydistributed within the polymer protuberances. In another embodiment, themedicinal nanoparticles are non-uniformly distributed within the polymerprotuberances. In another embodiment, the medicinal nanoparticles have avarying concentration from the tip of the polymer protuberances to thebase of the polymer protuberances.

In another embodiment, the medicinal nanoparticles includeanti-microbial, anti-fungal, anti-biotic, and/or growth-promotingagents. In another embodiment, the growth-promoting agents compriseInterleukins (IL-6, IL-7, IL-8), Keratinocyte growth factor (KGF) and/orHepatocyte growth factor (HGF).

In another embodiment, the medicinal nanoparticles are spherical inshape with a diameter ranging from 2 nm to 500 nm.

In another embodiment, the biodegradable polymer comprises PLA, PGA,PEG, PLGA, PGSA, and/or combinations thereof. In another embodiment, thebiocompatible polymer is comprised of PEDOT.

In another embodiment, the molecular weight of the polymer in thepolymer protuberances is chosen to optimize the controlled release rateof medicinal nanoparticles into the wound. In another embodiment, thespacing and size of the polymer protuberances are selected so as to makethe primary dressing surface superhydrophobic.

In another embodiment, the wound dressing further comprises an outercover and at least one layer located between the primary dressing andthe cover.

In another embodiment, the outer cover is comprised of a polymer, chosenfrom latex, mylar, polyethylene, polypropylene, nylon, rayon and/orcombinations thereof.

In another embodiment, the polymer protuberances release the medicinalnanoparticles as a result of a stimulus.

In another embodiment, the stimulus comprises a saline rinse, a changein temperature, sweat or perspiration, wound electrolytes, an electricalfield, a magnetic field, or any combination of the foregoing.

In one further embodiment, there is disclosed a dermal drug deliveryplatform comprising an enhanced wound dressing comprising nanopillarsand/or micropillars that extend upward from the dressing surface toengage the wound, and containing non-metallic and/or metallicnanoparticles. When the nanoparticles are metallic, they providegalvanic action when in contact with an electrolyte contained in thewound. While not necessary, the galvanic action can lead to enhancedwound healing via electrical wound stimulation.

Another aspect is a method of making the dermal drug delivery platformcomprising: dispersing medicinal nanoparticles in at least onebiocompatible and/or biodegradable polymer; and depositing saidmedicinal nanoparticle containing polymer onto a primary dressingsurface to form three-dimensional polymer protuberances.

Another embodiment is further comprises placing one or more secondarylayers over the primary dressing on the side opposite thethree-dimensional polymer protuberances. Another embodiment comprisesplacing an outer layer on top of the secondary layers, such that thesecondary layers are located between the primary dressing and the outerlayer.

In another embodiment, the polymer protuberances comprisemultiple-species, and are formed by a method comprising: depositing afirst polymer layer containing medicinal nanoparticles onto the primarydressing surface; depositing a second polymer layer containing medicinalnanoparticles overtop of the first polymer layer; depositing a thirdpolymer layer containing medicinal nanoparticles overtop of the secondpolymer layer; and pressing a heated mold with a complementary patternof pits against the primary dressing surface and the first, second, andthird polymer layers to form a pattern of multiple-specie polymerprotuberances.

In another embodiment, the first polymer layer comprises zincnanoparticles in PLGA; the second polymer layer comprises silvernanoparticles in PLGA; and the third polymer layer comprisesanti-microbial agents, anti-fungal agents, anti-biotic agents,germicidal agents, anti-bacterial agents, growth-promoting agents and/orcombinations thereof.

In another embodiment, the mold is made from silicon and includes anon-stick layer.

In another embodiment, the polymer protuberances are in the shape of atapered cone.

In another embodiment, the polymer protuberances are formed by a methodcomprising: depositing a first polymer layer containing medicinalnanoparticles onto the primary dressing surface; placing a mask over topof and proximal to the first polymer layer, wherein said mask has apattern with openings to allow light to pass there-through; exposing thefirst polymer layer to UV light to cure the polymer in the mask openingsonly, leaving the areas not exposed to UV light uncured; removing theuncured areas of the first polymer layer thereby forming a first patternof polymer protuberances; depositing a second polymer layer containingmedicinal nanoparticles onto the primary dressing surface; placing amask over top of and proximal to the second polymer layer, wherein saidmask has a pattern with openings to allow light to pass there-through;exposing the second polymer layer to UV light to cure the polymer in themask openings only, leaving the areas not exposed to UV light uncured;removing the uncured areas of the second polymer layer thereby forming asecond pattern of polymer protuberances different from the firstpattern; depositing a third polymer layer containing medicinalnanoparticles onto the primary dressing surface; placing a mask over topof and proximal to the third polymer layer, wherein said mask has apattern with openings to allow light to pass there-through; exposing thethird polymer layer to UV light to cure the polymer in the mask openingsonly, leaving the areas not exposed to UV light uncured; removing theuncured areas of the third polymer layer thereby forming a third patternof polymer protuberances different from both the first pattern and thesecond pattern.

In one embodiment, at least one of the first, second, or third polymercomprises PGSA.

In one embodiment, the first medicinal nanoparticle comprises silver;the second medicinal nanoparticle comprises zinc; and the thirdmedicinal nanoparticle is selected from anti-microbial agents,anti-fungal agents, anti-biotic agents, germicidal and/or anti-bacterialagents, and/or combinations thereof.

Another embodiment is for a three-dimensional method of treating awound, said method comprising: covering said wound with the dermal drugdelivery platform comprising: a primary wound dressing comprisingthree-dimensional polymer protuberances that extend upward from thedressing surface to engage the wound, wherein the protuberances compriseat least one biocompatible and/or biodegradable polymer and medicinalnanoparticles, and inserting said polymer protuberances into the woundto make direct contact with the wound.

In one embodiment, the biocompatible and/or biodegradable polymerdissolves in the wound and thereby releases said medicinal nanoparticlesinto the wound.

In one embodiment, the medicinal nanoparticles facilitate galvanicaction between said protuberances and at least one wound electrolyte.

In one embodiment, the medicinal nanoparticles comprise silver, gold,copper, zinc, platinum, palladium and combinations thereof; and thewound exudate comprises an electrolyte.

In one embodiment, the biodegradable polymer is selected from: PLA, PGA,PEG, PLGA and/or PGSA; and the biocompatible polymer is comprised ofPEDOT.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the disclosure are shown in thedrawings described below, and the detailed description that followsthereafter.

FIG. 1 depicts one embodiment of a nano-enhanced wound dressing systemwherein three (3) species of nanoparticle containing, biodegradable,micropillars are spread across the surface of the primary dressing tomake it actively anti-microbial.

FIG. 2 depicts a conventional, prior art adhesive bandage system withprimary dressing and adhesive strip.

FIG. 3 depicts an illustration of possible cross-section shapes for themicropillars including square, rectangular, round, hexagonal, ellipticaland non-specific.

FIG. 4 depicts an image of cellular growth on a surface comprisinggrooves.

FIG. 5 depicts a droplet of water on a surface with different wettingparameters.

FIG. 6 depicts several important steps in the process of nano-imprintlithography (NIL), one possible method of fabricating the nano-enhancedwound dressing.

FIG. 7 depicts a DIC microscope image of micropillars fashioned fromsilicon that can be used as a master mold.

FIGS. 8A-8R depict various steps in one embodiment for a process formaking a nano-enhanced wound dressing system according to an embodiment.

FIG. 9A depicts a perforated primary dressing surface according to anembodiment.

FIG. 9B depicts a close-up view of the same perforated primary dressingsurface of FIG. 9A.

FIG. 9C depicts two types of micropillars arranged into aniso(sceles)-hexagonal geometry.

FIG. 9D depicts two types of micropillars arranged into a concentriccircular geometry.

FIG. 9E depicts a close-up view of a primary dressing surface withhexagonal perforations and 3 types of micropillars contained thereon andarranged into an iso-hexagonal geometry.

FIG. 9F depicts an embodiment for a close-up view of a primary dressingsurface with circular perforations and 2 types of micropillars containedthereon and arranged into a concentric circular geometry.

FIG. 10 depicts an embodiment for two micropillars (out of manymicropillars on the primary dressing surface) that “communicate”electrically with each other thereby forming a galvanic cell.

DETAILED DESCRIPTION

Definitions:

As used herein and throughout, the term “wound” refers to, but is notlimited to, any cut, incision, slash, gash, lesion, laceration,puncture, abrasion, scrape, bruise, crack, trauma, contusion, burn,ulcer, amputation, or tissue damage of any kind, of, or pertaining to,the skin.

Wounds can be quantitatively characterized by a number of differentparameters such as their: type (acute versus chronic, open versusclosed, etc), lateral extent (including the size and shape of thewound), degree of severity (including the depth into the epidermis ordermis), location (on the body), phase of healing, time lapse sinceoccurrence, volume flow-rate and quality of exudate, pH, moisture(including humidity), electrochemical properties (voltage, current,etc), scab formation (if any), blood flow/vascularization, epithelialgrowth rate, oxygenation, temperature, condition of the patient (age,health, hydration, hormonal balance, comorbidities, etc), and color(appearance), among other things.

A wound will typically exhibit three (3) overlapping phases during thehealing process. During the first phase, the so-called inflammatoryphase, both hemostasis (stoppage of bleeding) and phagocytosis(engulfing and ingesting unwanted bacteria or foreign debris) areinitiated. During the second phase, the so-called proliferation phase,new blood vessels are formed (angiogenesis), fibroblasts excretecollagen and fibronectin (to form a new extracellular matrix ECM) withgranulation, epithelialization and wound contraction resulting. In thelast phase, the so-called remodeling phase, collagen production isslowed with greater organization (i.e. alignment along tensile lines) tostrengthen the tissue.

As used herein and throughout, the phrase “dermal drug deliveryplatform” refers to a system to facilitate the healing of a wound bytransmitting medicine directly to the wound via an enhanced wounddressing. The enhanced wound dressing can comprise medicinalnanoparticles contained in polymer protuberances that are configured toextend into a wound when the dressing is applied to the skin, and canrelease their medicinal nanoparticles when the polymer dissolves.

As used herein and throughout, the term “dressing” refers to, but is notlimited to, any surface that is brought into direct contact with a woundfor purposes of helping to heal the wound or preventing additional harm,including those from infection, contamination, and/or otherenvironmental/physical factors such as bumping, hitting or scratching.

As used herein and throughout, the term “bandage” refers to, but is notlimited to a dressing and some means for holding the dressing in placeagainst the skin.

As used herein and throughout, the term “primary dressing” refers to,but is not limited to, a dressing which is placed in direct contact withthe wound surface.

As used herein and throughout, the term “secondary dressing” refers to,but is not limited to, a dressing which is in contact with the primarydressing but not necessarily in direct contact with the wound surface. Asecondary dressing may, for example, be deployed in-between the primarydressing and the outer covering of the bandage for purposes of moisturemanagement.

As used herein and throughout, the term “exudate” or “wound exudate”(also sometimes called wound “drainage”) refers to, but is not limitedto the natural liquid produced by the body in response to tissue damage.Wound exudate bathes the wound (i.e. keeps it moist) and supplies vitalnutrients to the wound bed thereby facilitating optimal healingconditions.

As used herein and throughout, the term “anti-microbial surface” refersto, but is not limited to, those surfaces that are useful in avoiding,preventing and/or treating bacterial, fungal and/or microbial infectionsby releasing certain substances (aka anti-bacterial, anti-fungal and/oranti-bacterial substances) that are effective at suppressing the growthof such organisms.

As used herein, the phrase “galvanic action” refers to the movement ofelectrons and ions that occurs when two electrochemically dissimilarmetals are immersed in an electrolyte. One non-limiting example ofgalvanic action occurs when cathode-like metals, such as silver, andanode like metals, such as zinc, are immersed in wound electrolyte. Thismethod of introducing metallic ions into the wound system isparticularly useful because it does not require an external powersupply.

As used herein and throughout, the term “nano” refers to one-billionth(1×10⁻⁹) of the unit of measure that follows. For example, there areone-billion nanometers (nm) in one meter and 1000 nanometers (nm) in amicron (μm).

As used herein and throughout, the term “micro” refers to one-millionth(1×10⁻⁶) of the unit of measure that follows. For example, there areone-million micrometers (μm) in one meter and 1000 micrometers (μm) in amillimeter (mm). Microns and micrometers shall be used interchangeably.

As used herein and throughout, the term “pillar” refers to a threedimensional structure, such as a column, having an aspect ratio in whichthe height is greater than both the length and the width.

As used herein, and throughout, the terms “micropillar” and “nanopillar”refers to a “pillar,” as defined above, in which the height is either onthe micrometer scale (micropillar) or on the nanometer scale(nanopillar).

As used herein and throughout, the term “protuberance” refers to, but isnot limited to, any protrusion of any shape that extends upward from thedressing surface to engage the wound. For example, the protuberance mayhave an elongated rectangular shape to form walls of polymer that extendupward from the primary dressing surface. When viewed in cross-section,this will appear as grooves between each wall structure. In anotherembodiment, the protuberances may have a column or pillar shape aspreviously described, wherein the column or pillar has a base with anyof a variety of shapes, including but not limited to round, square,rectangular, hexagonal, elliptical, completely general, or combinationsthereof.

As used herein and throughout, the “tip” of the polymer protuberance isdefined as the distal end of the protuberance. As the tip is farthestaway from the primary dressing, it is more likely to engage the woundbefore any other part of the protuberance.

As used herein and throughout, the “base” of the polymer protuberance isdefined as the proximal end of the protuberance. The base of theprotuberance is attached to the primary dressing.

As used herein and throughout, the term “hot embossing” refers to aprocess of stamping a pattern into a polymer layer that has beensoftened by temporarily raising its temperature above the polymer'sglass transition temperature. One non-limiting embodiment of the stampthat can be used is one that is micro-machined out of silicon.

As used herein and throughout, a “hydrophobic surface” is one that isnot easily wetted (i.e. one that repels water). Silicon is a hydrophobicmaterial, as are most polymers.

As used herein and throughout, a “hydrophilic surface” is one that iseasily wetted (i.e. one that invites water to spread out across thewhole surface). Oxide, or more precisely, silicon dioxide, is ahydrophilic surface.

As used herein and throughout a “superhydrophobic surface” is one thatexhibits extreme water-repellency, with water droplets that rest uponthem with very large contact angles.

A variety of skins and wounds can be treated with the articles andmethods described herein. Mammalian skin and wounds therein are commonexamples. Mammalian skin is comprised of three different layers. Theoutermost layer (the epidermis) protects the body from the outsideenvironment. Just beneath the epidermis lies the dermis which consistsof an extracellular collagen matrix, nerve endings, lymphatic and bloodvessels, sweat glands and hair follicles, among other things. Beneaththe dermis lies a subcutaneous fat layer which helps to prevent heatloss.

Dermal Drug Delivery Platform

There is disclosed herein a dermal drug delivery platform used as anenhanced wound-healing system to treat these various types of woundscomprising a primary dressing surface comprising biocompatible and/orbiodegradable polymer protuberances, wherein a majority of the polymerprotuberances comprise medicinal nanoparticles.

The nano-enhanced wound dressing described herein, e.g., with a patternof protuberances engaging the wound system, provides numerous advantagesin wound care over existing dressings including, but not limited to oneor more of the following, including combinations thereof:

A nano-enhanced wound dressing in the form of nano and/or micropillarsmade from (or containing) silver, zinc or other metals, when broughtinto contact with the wound exudate, will produce galvanic microcurrentsfor stimulating the wound healing process.

A nano-enhanced wound dressing in the form of nanopillars and/ormicropillars made from a biodegradable polymer and containing silver,zinc or other metals will result in a sustained release of theseantimicrobial constituents at therapeutic levels. As the polymerdissolves away, the infused metals will be released into the wound in acontrolled manner.

A nano-enhanced wound dressing in the form of nanopillars and/ormicropillars brought into contact with the wound can (under certaincircumstances) provide a fertile “scaffold” for new cells to growwithin.

A nano-enhanced wound dressing in the form of nanopillars and/ormicropillars brought into contact with the wound can be made todifferentiate between “good” cells and “bad” cells.

A nano-enhanced wound dressing according to the present disclosure mayallow superhydrophobic wetting properties to be used in the overallmoisture management of the wound/dressing system. Superhydrophobic (i.e.highly non-wetting) surfaces do not wick away moisture as in the case oftraditional fabrics/textiles. And these wetting properties can be tuned,depending on the details of the nano-textured surface.

A nano-enhanced wound dressing according to the present disclosure mayfacilitate skin cell growth preferentially faster in one direction thananother, to better match the shape of the wound bed.

A nano-enhanced wound dressing according to the present disclosure mayfacilitate an anesthetic response for the reduction of pain associatedwith the wound.

A nano-enhanced wound dressing in the form of nanopillars and/ormicropillars brought into contact with the wound bed increases thecontact area many times (over that of a flat surface) which enhances thegalvanic microcurrent and the amount of silver ions that are forced intothe wound.

Depending on the molecular weight of the biodegradable polymer used tofabricate the nanopillars and/or micropillars, they can dissolve quicklyover time or dissolve more slowly, thus allowing a tunable release rateof the infused metal (silver, zinc, etc) nanoparticles.

A nano-enhanced wound dressing in the form of biodegradable nanopillarsand/or micropillars brought into contact with the wound surface isamenable to future medical innovations in that advanced medicinals canbe slowly released as a result of the dissolving pillars.

A nano-enhanced wound dressing in the form of biodegradable nanopillarsand/or micropillars brought into contact with the wound surface couldallow tailored degradation profiles wherein the release of silver ionsor the wicking action of the dressing surface can be controlled over alonger period of time.

A nano-enhanced wound dressing according to the present disclosure maybenefit persons with poor blood circulation in that the wound will stayoptimally moist, with more anti-microbials and an advanced rate ofhealing due to galvanic microcurrents.

A nano-enhanced wound dressing according to the present disclosure isable to address a larger percentage of the population with anever-increasing diversity of wound care needs.

A nano-enhanced wound dressing according to the present disclosure isamenable for use on virtually any surface that would come into contactwith biological electrolyte material. The nanopillars and/ormicropillars can be transferred onto a flat surface, a curved surface(in the case of a catheter) or a fabric surface.

Galvanic action will not begin until after the dressing comes intocontact with the wound exudate. Alternatively, it could be activated bysweat (aka perspiration) or a saline rinse. Prior to that, the productwill have a long shelf (aka storage) life

A nano-enhanced wound dressing according to the present disclosure canbe made to release various medicinal agents at different rates/timesthroughout the lifecycle of the dressing and/or healing process. Forexample, medicinal specie 1 can be released immediately upon placing thedressing in contact with the wound and medicinal specie 2 can bereleased several days after that. In this way, the dressing can beoptimized for the shortest possible overall healing time.

A nano-enhanced wound dressing according to the present disclosure couldbe designed to release the medicinal constituents in response to bodytemperature.

A nano-enhanced wound dressing according to the present disclosure couldbe designed to release the medicinal constituents in response to someother external stimulus, such as an electric field or a magnetic field.

Traditional Adhesive Bandage System

The traditional Adhesive Bandage 11 (see FIG. 2) is comprised of anAdhesive Strip 12 on opposing sides of the Dressing 13. The Dressing 13can be further comprised of any number of Primary, Secondary, Tertiary,etc., dressing layers.

Wound exudate may include one or more of electrolytes, glucose,cytokines, leukocytes, metalloproteinases, macrophages, platelets,fibrin and micro-organisms, among other things.

Types of wound exudate include: serous (clear, amber, thin and watery),fibrinous (thin and cloudy with strands of fibrin), serosanguineous(clear, pink, thin and watery), sanguineous (reddish, thin and watery),seropurulent (yellow or tan, cloudy and thick), purulent (opaque andmilky), hemopurulent (reddish, milky and viscous) and hemorrhagic (redand thick).

With reference to FIG. 2, the Primary Dressing 13 is used to help stopbleeding, absorb blood/wound exudate, ease pain, debride the wound,protect the wound from infection and to generally promote the healingprocess in whatever way possible, among other things.

The Adhesive Strip 12 is used to secure the Dressing (including thePrimary Dressing, the Secondary Dressing and Other Dressing Layers)against the wound. The Adhesive Strip 12 sometimes comes in the form ofvinyl tape.

The Primary Dressing 13 can be made of cotton gauze or blendedrayon/polyester, among other things. The Primary Dressing 13 often comesin the form of an absorbent pad.

Preferably, but not necessarily, the Primary Dressing is encapsulatedwithin a non-stick coating such as polyethylene terephthalate to preventthe material from sticking to the wound. In such cases, the coatedmaterial is perforated to allow fluid to seep into the dressing asneeded.

Adhesive Bandages are typically sterilized using Gamma Radiation.

Electrical Potential of Human Skin

Healthy human skin typically exhibits an electrical potential across theepithelium (the transepithelial potential or TEP for short). And, theinner-most workings of this “epidermal battery” are jeopardized in theevent of a wound.

As early as 1964, Winter (“Movement of Epidermal Cells Over the WoundSurface”, Advances in Biology of the Skin, Vol. 5, p. 113, 1964) showedthat the cells migrating across a wound come from the 0.5 mm wideperipheral region around the wound where substantial voltage gradientsexist. He and other researchers at the time suggested that maybe theepithelial cells move under the influence of these voltages, along thedirection of current flow. Wheeler et al. (“Neural Considerations in theHealing of Ulcerated Tissue by Clinical Electrotherapeutic Applicationof Weak Direct Current: Findings and Theory”, Neuroelectric Research, p.83, 1971) was arguably the first to suggest that electrical stimulationcould be used to encourage wound healing.

In 1983, Foulds et al. (“Human Skin Battery Potentials and TheirPossible Role in Wound Healing”, British Journal of Dermatology, Vol.109, p. 515, 1983) measured an average potential of 23.4 mV (between thestratum corneum and the dermis) at many different locations across thebody. He also showed that the palms of the hands (36.9 mV) and soles ofthe feet (39.0 mV) exhibited consistently higher voltages.

In 1990, Weiss et al. (Archives of Dermatology, Vol. 126, February 1990,P. 222) summarized well that electrical stimuli can be used toaccelerate the healing process.

Cell Response to Nano-Textured Surfaces

In 1994, Rovensky et al. (Journal of Cell Science, Vol. 107, p. 1255)showed that cells cultured on cylindrical surfaces with a high degree ofcurvature affected their size, shape and orientation. In addition,Rovensky and his colleagues discovered that certain cells were moreaffected than others by this surface geometry.

Also in 1994, Green et al. (Journal of Biomedical Materials Research,Vol. 28, p. 647, 1994) found that cells exhibited increased rates ofproliferation on pillars as compared to equivalent-sized trenches.

In 1997, Chen et al. (Science, Vol. 276, May 1997, p. 1425) usedmicrocontact printing methods to form circular/square fibronectin-coatedislands. They found that endothelial cells would grow until they took onthe size and shape of the island, with a marked decrease in apoptosis(cell termination) for larger islands as compared to smaller islands.

In 2012, Rajput et al. (Colloids and Surfaces B: Biointerfaces, Vol.102, P. 111, 2013) reported that “when surface topographical featuresare considerably larger in vertical dimension and are spaced at leastone cell dimension apart, the features act as 3D physical barriers thatcan guide cell adhesion, thereby altering cell behavior”.

Few researchers would argue that the growth of cells on a surface candepend on the nano-topography of said surface. For example, FIG. 4 showsCell Attachment and Spreading on a grooved surface.

Surface topography can depend on the: size (length, width, diameter,height) of the features formed thereon, including their cross-sectionalshape (square, rectangular, spherical, elliptical, etc), relief tone(hill vs valley), spacing (from peak to peak or valley to valley),sidewall condition (straight, reentrant, sloped, tapered, etc), amongmany other things.

FIG. 3 shows various Pillar cross sections including Square 21,Rectangular 22, Hexagonal 23, Round 24, Elliptical 25 and General 26.Any of these and more can be achieved using modern lithographictechniques.

On the nanometer and/or micron scale, the parameters of a texturedsurface might be selected to: (1) Stimulate the growth rate of cellsbeyond that which could be achieved on a flat surface, (2)Preferentially grow beneficial cells while hindering the growth ofunwanted cells, and (3) Control the growth rate of new cells indifferent directions so as to match the shape of the wound bed.

Wu et al. (Biotechnology Letters, Vol. 33, No. 2, p. 423, 2010)describes cell growth on a honeycomb structure of PLGA. In their work,osteoblast-like MG63 cells were cultured on PLGA scaffolds with greaterviability as compared to the control surface. This was an importantresult as that surface geometry can play a role in the rate of cellgrowth.

Biazar et al. (Journal of Paramedical Sciences, Vol. 1, No. 4, 2010, p.74) was able to pattern a polyhydroxybutyrate-co-hydroxyvalerate (PHBV)film into micro-grooves and showed that subsequent cell growth could bealigned along the preferential direction of the grooves.

Biocompatible and Biodegradable Polymers

As used herein and throughout, the term Biocompatible Polymer shallinclude any polymer that, when placed in direct contact with mammaliantissue, is nontoxic, non-allergenic, non-carcinogenic, non-mutagenicand/or does not cause any adverse reactions or side-effects in theadjacent tissue.

Preferably, but not necessarily, Biocompatible Polymers for use innanopillar fabrication will include Polyvinylchloride (PVC),Polytetrafluoroethylene (PTFE), Polyethersulfone (PES), Polyethylene(PE), Polyurethane (PU), Polyetherimide (PEI), Polycarbonate (PC),Polyetheretherketone (PEEK), Polysulphone (PS), Polypropylene (PP),Polymethylmethacrylate (PMMA), Polydimethylsiloxane (PDMS),Polyhydroxybutyrate-co-hydroxyvalerate (PHBV) and/or combinationsthereof.

PDMS is commercially available under the tradename of Sylgard™ and ismanufactured by the Dow Corning Corporation (Midland, Mich.).

A particularly preferable Biocompatible and Electrically Conductivepolymer is polyethylenedioxythiophene (PEDOT). Other conductive orconjugated polymers can be used including other polythiophenes and otherheterocyclic polymers.

As used herein and throughout, the term Biodegradable Polymer shallinclude any polymer that, when placed in direct contact with livingtissue slowly dissolves away with no adverse reactions or side-effectsto the adjacent tissue.

In one embodiment, Biodegradable Polymers for use in nanopillar and/ormicropillar fabrication will include Polylactic Acid (PLA), PolyglycolicAcid (PGA), Polyethylene glycol (PEG), Polylactic-co-glycolic acid(PLGA) and/or combinations thereof. PLGA is commercially available fromEvonik Industries AG (Darmstadt, Germany).

A particularly preferable Biodegradable and UV curable Polymer is Polyglycerol-co-sebacate acrylate (PGSA). See for example, Nijst, Bruggeman,Karp, Ferreira, Zumbuehl, Bettinger and Langer, “Synthesis andCharacterization of Photocurable Elastomers fromPoly(glycerol-co-sebacate)”, Biomacromolecules, Vol. 8, No. 10, p. 3067,October 2007).

Superhydrophobic Surfaces and Moisture

Consider the interface between a small liquid droplet and an ideal solidflat surface on a length scale greater than 50 Å, where van der Waalsand electrostatic forces play an important role. In this system, thereare typically three distinct wetting regimes: (1) non-wetting with acontact angle of θ≈180 deg (5 a), (2) partial-wetting with a contactangle 0<θ<180, and (3) complete-wetting where θ≈0 as shown in FIG. 5(d).

From energy considerations, it can be shown that the contact angle θ atthe “triple-point” is defined by Young's equation such thatγ_(SV)−γ_(SL)−γ_(LV)*cos θ=0 where γ_(i,j) (i,j=SV, SL, LV) is thesurface tension (energy per unit surface area) for the Solid-Vapor,Solid-Liquid and Liquid-Vapor interfaces respectively. FIG. 5 depictsthe wetting properties of a water droplet on a flat and texturedsurface. As the contact angle θ increases beyond 150 degrees, thesurface becomes Superhydrophobic (extraordinarily water-repellent).

Aside from keeping the wound clean, Moisture Management of a wound isperhaps the most important and elusive of modern-day dressings. Somedressings will wick away moisture at too high a rate, leaving the woundoverly dry. Other fabrics will not wick away enough moisture, leavingbehind an attractive environment for microbes, fungi and other harmfuldetractors to wound healing.

Nano-engineered dressing surfaces bring an important additionalparameter that can be used to optimize the rate at which moisture isbeing pulled away from the wound. In the present disclosure, thewettability of a nano-textured surface is controllable. By changing thesize and pitch of the features patterned onto the primary dressingsurface, including the perforations contained therein, we can directlycontrol the rate at which moisture is wicked away from the wound.

Hydrophobicity is usually determined experimentally by measuring thecontact angle of a water (or other liquid) droplet contacting thesurface under study. The angle between the surface tangent and the watermeniscus near the line of contact, measured within the droplet, gives anindication of the wettability of the surface.

For example, the water contact angle on a flat surface coated with PTFEis approximately 120 degrees. This is nominally the maximum contactangle for water on a flat (i.e. non-textured) surface. Superhydrophobicsurfaces typically have a contact angle of 150 degrees or greater andrequire patterning of the surface to achieve these parameters.

Martines et al. (Nano Letters, Vol. 5, No. 10, p. 2097, 2005) has shownthat a forest of slender nanopillars is a highly effectivewater-repellent surface and that the repellency is dependent on thegeometric parameters of said surface. That being said, it seemsreasonable to assume that the surface patterns can be selected toachieve the optimal wetting characteristics for longer-term managementof dressing moisture.

The Galvanic Cell

The galvanic cell is an electrochemical device that derives electricalenergy from a chemical reaction taking place within it. Typically, agalvanic cell is comprised of two different metal electrodes immersed inan electrolyte solution. The so-called “Lemon Battery” and “PotatoBattery” are examples of simple galvanic cells

For a galvanic cell comprised of Silver (Ag) and Zinc (Zn) Electrodes,the Redox reaction is given by:Zn_((s))+2Ag¹⁺ _((aq))→Zn²⁺ _((aq))+2Ag_((s))where Zinc (the Anode) losses 2 electrons (Oxidation) and Silver (theCathode) gains 2 electrons (Reduction).

Alternative electrodes could be comprised of other metals found in theso-called “electromotive series”:

K, Na, Ba, Ca, Mg, Al, Mn, Zn, Cr, Cd, Fe, Ni, Sn, Pb, H, Sb, Bi, As,Cu, Hg, Ag, Pt where the more reactive elements are to the left and theless reactive elements are to the right.

Applying these concepts to the disclosed Nano-Enhanced Wound dressingsystem, electrons will travel from the Silver-containing micropillars tothe Zinc-containing micropillars through the primary dressing surfaceupon which they sit. And, ions (charged atoms) will be pushed (viaelectromotive force or EMF) into the wound electrolyte and subsequentlythe wound bed. In this way, there can be many more ions in the woundelectrolyte than there otherwise would be without galvanic action. Andthis causes a significant enhancement in anti-microbial action.

An important parameter for any galvanic cell (among other things) is thesurface area between the electrolyte and the two electrodes immersedtherein. When this surface area is increased, the amount of currentavailable increases and the current capacity (in uA-hrs) is alsoincreased. This is important in the context of a silver-containingdressing because the greater the surface area of contact, the moresilver ions will be “pushed” into the wound, with quicker healingresulting. In the disclosed embodiments, the numerous PolymerProtuberances that extend into the wound provide a far greater amount ofsurface area as compared to a flat surface, which forms the basis andmechanism for increased response.

When activated by saline solution (sodium chloride in water) and placedagainst the wound, the nano-enhanced dressing will exhibit galvanicaction to produce an electric voltage (and current) that is supplementaland supportive of the natural electrochemical reaction of the human skinin the presence of a wound, thereby facilitating the healing process.

FIG. 10 shows a schematic representation of how this three-dimensionalprocess can work. In particular, a Galvanic Cell comprised of twonano-particle containing micropillars are at least partly inserted intoa wound electrolyte wherein the micropillars are mounted onto aconductive Primary Dressing Surface (140) that also has metallicnanoparticles embedded therein (to make it conductive). Preferably, butnot necessarily, the micropillars contain nano-particles of silver andzinc. In this specific embodiment, the micropillars are comprised ofmultiple layers (110). In this embodiment, three layers are shown but itcould be many and each layer has a different volume fraction ofnanoparticles within. The micropillars can be tapered in one embodiment.As the pillar dissolves away over time, the first layer releases thenanoparticles contained therein. By changing the amount of nanoparticlesused in each layer, the release rate during the lifetime of the bandagecan change. For example, more nanoparticles can be located in thedeepest layer and fewer in the shallowest layer (or vice versa). Andthese layers can each have a different molecular weight, causing them todissolve at different rates.

The micropillars can also contain a uniform distribution ofnano-particles (120). In addition, the shape of the micropillars canchange, which will also affect the rate of dissolving. The narrow tip ofa cone will dissolve more quickly than a thick base. (120) As a result,the three-dimensional method is extremely flexible in that themicropillar shape, molecular weight (of the polymer), volume ofnanoparticles mixed into the polymer and layering all help to achievethe varying and beneficial release rate of medicinals.

With reference to FIG. 10, it is shown that d is the diameter of themicropillar, “h” is the height of the micropillar and “x” is thecenter-to-center distance from one micropillar (110) to a neighboringmicropillar (120).

Electrons flow between the micropillars in the conductive PrimaryDressing surface (to close the circuit) (130) and ions (160) flowbetween the micropillars inserted into the wound electrolyte to yield a3D current distribution inside the wound, and not just a surface effectas with prior art wound dressings. In particular, ions will flow fromthe surface-revealed nanoparticles into and out of the wound electrolyte(150) at various depths while electrons will flow in the conductivesurface of the primary dressing, to complete a single micro galvaniccell. And, there are many thousands to many millions of such microgalvanic cells integrated across the primary dressing surface thatinteract with the wound bed. In any single micro galvanic cell, thecurrent that flows is a function (by Ohms Law) of the electrochemicalpotential developed across the two micropillars (by virtue of thesurface-revealed metallic nanoparticles contained therein) and theresistance to electron flow in the primary dressing surface, which wecontrol by the volume (or weight) fraction of conductive nanoparticlescontained in/on the polymer used to fashion the primary dressing surface(which may, or may not, be the same polymers that are used to fashionthe micropillars) and the distance x between the micropillars. Also ofsignificant importance to the functioning of a micro galvanic cell isthe surface area of the micropillars in contact with the woundelectrolyte (πdh). A larger surface area means there are moresurface-revealed nanoparticles taking part in the galvanic process,thereby increasing the current capacity in uA-hrs. Since the polymercomprising the micropillars is dissolving (i.e. d is getting smaller intime due to biodegradation), as time passes, more and more of thenanoparticles contained therein are surface-revealed, thereby allowingthem to participate in the galvanic process.

Embodiments of the Disclosure

In an embodiment according to the present disclosure, a dermal drugdelivery platform is deployed as part of an advanced Adhesive Bandagesystem as illustrated in FIG. 1. In this example, an Adhesive BandageSystem 1 is comprised of a Nano-Enhanced Wound Dressing 2 that isfurther comprised of a Primary Dressing 3 and a Secondary Dressing 4held in abeyance against the wound bed 5 using Adhesive Strips (akaAdhesive Tabs) 6 on opposite sides of said Primary Dressing 3.

It is shown in FIG. 1 that on the wound-facing side of Primary Dressing3 there is an arrangement of Polymer Islands 7 formed thereupon. ThesePolymer Islands 7 are spaced apart on the Primary Dressing 3, so as toallow the dressing to remain conformable/pliable and to facilitate theflow of exudate through the dressing system as needed.

In one embodiment, the Primary Dressing 3 is a woven fabric and thePolymer Islands 7 are Hot Embossed into the woven surface.

The Polymer Islands 7 may be round, square, rectangular, elliptical orhexagonal in shape and they would be spaced across the Primary Dressing3 in an array, covering a substantial portion of the area.

In one embodiment, the Polymer Islands 7 would be fashioned from aconductive, biocompatible polymer.

It should be noted that regarding Polymer Island 7, there is anarrangement of nano and/or micro scale Polymer Protuberances 8 a, 8 b, 8c and/or 8 d formed thereupon wherein each polymer protuberance isfurther comprised of nanoparticles embedded within the polymer. In thisparticular example, Polymer Protuberances 8 a, 8 b and 8 c are embeddedwith Nanoparticles 9 a, 9 b and 9 c respectively. Or, as in the case of8 d, there could be several different layers of nanoparticles thatcomprise a single polymer protuberance. In either case, Nanoparticles 9a, 9 b and 9 c comprise equivalently a selection of Medicinal Species 9a, 9 b and 9 c respectively, that are contained within the PolymerProtuberances.

In an embodiment, the Nanoparticles (also known as “Medicinal Species”)would be selected from the following metallic species: Silver (Ag), Gold(Au), Copper (Cu), Platinum (Pt), Palladium (Pd), Zinc (Zn) and/orcombinations thereof.

Other materials to be incorporated into (or onto) the PolymerProtuberances as medicinal species might include: Amitriptyline,Amantadine, Baclofen, Bupivacaine, Clonidine, Cyclobenzaprine,Diclofenac, Gabapentin, Ketamine, Ketoprofen, Lidocaine, Menthol,Mexiletine, Morphine, Nifedipine, Orphenadrine, Phenytoin, Prilocalne,Tramadol, Verapamil, and growth factors including but not limited to,Interleukins (IL-6, IL-7, IL-8), Keratinocyte growth factor (KGF),Hepatocyte growth factor (HGF), and/or combinations thereof.

In one embodiment, the Nanoparticles may be spherical in shape with adiameter ranging from 2 nm to 500 nm.

In one embodiment, the Polymer Protuberances would take the form ofPillars, and the Pillars would have a cross sectional shape that issquare, round, elliptical, rectangular or general.

In one embodiment, the diameter (in the case of round pillars) or width(in the case of square pillars) ranging from 1 μm to 1000 μm.

In one embodiment, the height of the Polymer Protuberances range from 1μm and 500 μm so as to readily engage the wound bed.

In one embodiment, each Polymer Island 7 may comprise numerous (andtherefore smaller) Polymer Protuberances 8 a, 8 b, 8 c and/or 8 d formedthereupon, with any number of Medicinal Species 9 a, 9 b and 9 c infusedtherein as nanoparticles.

In one embodiment, Polymer Island 7 and/or Primary Dressing 3 mayfurther comprise numerous perforations that would aid in moisturemanagement.

In one embodiment, Primary Dressing 3 may comprise a material that isflexible and allows wound exudate to readily pass through it.

In one embodiment, Secondary Dressing 4 may comprise a material that isa reservoir for moisture and allows for additional moisture managementof the dressing system as a whole.

Also disclosed herein are the various methods of fabricating the dermaldrug delivery platform used for the Nano-Enhanced Wound dressings.Adhesive Bandages must be fabricated in high volume, they must beinexpensive and widely available.

One method of making the dermal drug delivery platform comprisesdispersing medicinal nanoparticles in at least one biocompatible and/orbiodegradable polymer; and depositing the medicinal nanoparticlecontaining polymer onto a primary dressing surface to formthree-dimensional polymer protuberance.

This method may further comprise placing one or more secondary layersover the primary dressing surface on the side opposite thethree-dimensional polymer protuberance, as well as placing an outerlayer on top of the secondary layers, such that the secondary layers arelocated between the primary dressing and the outer layer.

Among the several different candidate methods of fabrication,Nanoimprint Lithography (NIL), might play an important role. A schematicrepresentation of this is shown in FIG. 6, and is described inNanoimprint Lithography (see Chou et al. (Applied Physics Letters, Vol.67, p. 3114, 1995)). The method involves the use of a hard mold withnanoscale and/or microscale surface-relief features thereon (61) that ispressed against a polymer material (62) previously deposited onto asubstrate (63). Under the correct conditions of temperature, pressureand/or UV illumination, takes the shape of the mold surface (64), withunwanted polymer being removed from the substrate through an etchingstep, such as reactive ion etching, that exposes the substrate. (65)

Nanoimprint Lithography is particularly attractive because of itsinherently high-throughput and low-cost. Using NIL, large macroscopicregions with nanometer-sized features can be “printed” at the same time.The printed area is only dependent on the size of the mold master.

In one method of fabrication, a master mold is fashioned from a SiliconWafer using traditional lithographic methods including Contact, Opticaland/or Electron Beam (aka Ebeam) Lithography. Contact Lithography isused for surface features on the order of tens of microns down to 1 μm(nominally), Optical Lithography is used for surface features on theorder of 1 micron down to 200 nm (nominally) and Ebeam Lithography isused for surface features on the order of 200 nm down to 10 nm(nominally). When making the master mold, resist is spun onto a siliconwafer surface and exposed through a mask so that certain features areexposed with ultra-violet (UV) light and others are not (depending onthe openings in the mask). Those features in the (positive) resist thatare exposed with UV light will dissolve readily in developer solution.Those regions in the (positive) resist that are unexposed will remainafter development. Once the pattern in the mask is transferred into theresist layer on the silicon wafer (i.e. there are “patterned openings”in the resist layer that correspond to the patterned openings in themask), we use Reactive Ion Etching (RIE) or Deep Reactive Ion Etching(DRIE) methods to etch the pattern into the surface of the silicon wafer(the master mold surface, see FIG. 7). After the etching of the siliconis completed, any remaining resist is removed using wet solvent and/orOxygen Plasma cleaning methods. At this time, the master mold has apattern on it that is complementary to the pattern of interest. Forexample, if the Polymer Protuberances are to be tapered cones, as shownin FIG. 1, the master mold would have tapered pits on the surface.

Prior to using the master mold, a non-stick (aka release) agent (such asTeflon or Perfluorooctytrichlorosilane (FOTS)) is deposited onto itssurface, so that the imprinted polymer doesn't stick to the moldsurface. The mold will presumably be used many times over and we need tokeep it free of residue buildup.

In one embodiment, the master mold would be used to make numeroussecondary molds and only the secondary molds would be used in theimprinting process thereby extending the life of the master moldindefinitely.

After the master mold is completed (with whatever nano and ormicro-textured surface features fabricated thereon), medicinal species 1nanoparticles are mixed into a solvent along with polymer granules andmagnetically stirred to form a species 1, semi-viscous polymer liquid.This procedure can be continued with species 2, semi-viscous polymerliquid, etc.

In one embodiment, the polymer granules may be comprised of PLGA.

In one embodiment, the medicinal species 1 nanoparticles will becomprised of silver, and the medicinal species 2 nanoparticles will becomprised of zinc.

In one embodiment, the solvent is comprised of: acetone, toluene,methanol, ethanol, isopropyl alcohol (IPA), nmethylpyrrolidone (NMP),propylene glycol (PG), propylene glycol methyl ethyl acetate (PGMEA) orcombinations thereof.

Silver nanoparticles are available from NanoComposix (San Diego, Calif.)or Ted Pella Inc (Redding, Calif.).

Gold nanoparticles with diameters of: 5, 7, 10, 12, 15, 17, 20, 30, 40,40, 60, 70, 80, 90 and 100 nm are available from Ted Pella Inc (Redding,Calif.). Gold nanoparticles as small as 2 nm are available from BBISolutions (Cardiff, UK).

Zinc nanoparticles in the form of a gray powder with diameters between30-60 nm and 60-80 nm are available from Nanoshel (Wilmington, Del.).Other metal nanoparticles available from Nanoshel include: Silver,Aluminum, Gold, Platinum, Titanium, Boron and several alloys such asCu/Zn, Ni/Ti and Fe/Ni to name a few.

Silicon wafers are then prepared by first depositing and/or growing aRelease Layer thereupon. The Release Layer might be comprised of:Thermal Oxide, LPCVD Oxide, PECVD Oxide, Sputtered Oxide, EvaporatedOxide, LPCVD Poly Silicon, PECVD Amorphous Silicon, or any one of anumber of different metals (Aluminum, Gold, Chrome, Titanium, etc), orany one of a number of different polymers (Resist, Omnicoat, etc).

Following this, the specie 1 laden liquid polymer is spun, sprayed orotherwise deposited over-top of the Release Layer.

Following this, the specie 2 laden liquid polymer is spun, sprayed orotherwise deposited over the specie 1 laden liquid polymer, etc. In thisway, there are multiple layers of different medicinal species, one overtop of the next.

Preferably, but not necessarily, the polymer deposition method of choicewill be: Spin Coating, Spray Coating, Silk-Screen Printing, Ink-JetPrinting, Slot-Die Coating, Gravure Printing, Flexo Printing and/orcombinations of the above.

Spin Coaters, such as the Cee 200X , are available from Brewer ScienceInc. (Rolla, Mo.) to spin a nanoparticle-infused liquid polymer layeronto a surface.

Spray Coaters, such as the AltaSpray Module in the Suss Gamma Custer(Suss MicroTec AG, Garching, Germany), can be used to coat virtually anysurface with a nanoparticle-infused liquid polymer layer onto a surface.

Following this, the master mold is pressed against the silicon waferunder controlled conditions of pressure and temperature wherein themultiple layers will reflow (i.e. fill-in all the little nooks andcrannies on the mold surface).

After heating, pressing and/or uv-curing, the master mold is pulled awayfrom the Silicon Wafer with the desired surface (an array of polymerprotuberances) embossed into the multiple polymer layers.

Following this, a Release Agent (Buffered Oxide Etch (BOE) or Vapor HFin the case of an Oxide Release Layer, KOH or XeF2 RIE in the case of aSilicon Release Layer, or any number of different metal etchants(Aluminum Etch, Gold Etch, etc) in the case of a Metal Release Layer orsolvents (Acetone, Toluene, PGMEA, etc) in the case of a Polymer ReleaseLayer)) is used to Lift-Off the freshly-molded multiple-specie polymerprotuberance layer. After Lift-Off and Harvesting of the multiple-speciepolymer protuberance layer, it can be applied to the dressing surface(thereby converting a conventional dressing surface into a nano-enhanceddressing surface) and/or any other surface that requires anti-microbialaction.

An alternative to Lift-Off, Harvesting and Application of themultiple-specie, polymer protuberance layer is to hot emboss the polymerprotuberances directly onto the dressing fabric surface. In thisscenario, the specie-laden polymer is spun, sprayed or otherwisedeposited onto the dressing fabric and a mold is pressed against thepolymer/fabric under the correct conditions of temperature and pressureuntil the polymer reflows both into the dressing fabric and the nooksand crannies of the mold surface.

In yet another preferred method of fabrication, a Pillar Array is UVImprinted onto the Primary Dressing Surface (see for example, Shinohara,Goto, Kasahara and Mizuno, “Fabrication of a Polymer High-Aspect-RatioPillar Array using UV Imprinting, Micromachines, Vol. 4, p. 157, 2013).In this method, a biocompatible polymer is silk screened onto thePrimary Dressing Surface to form a pattern of millimeter-sized PolymerIslands. Following this, the Primary Dressing Surface would becompressed against a flat heated surface in such a manner so that thePolymer Islands would locally fuse the textile threads beneath them, andin so doing, each Polymer Island would exhibit a flat surface on whichthe Polymer Protuberances will be subsequently formed. In-between thefused Polymer Islands would be conventional dressing materials thatallow the overall dressing to remain conformable on a macroscopic scale.

Preferably, but not necessarily, the biocompatible polymer isconductive.

In one embodiment, the biocompatible polymer is PEDOT or PLGA containingmetallic nanoparticles.

After forming the flat islands (i.e. the substrates) across the primarydressing surface, medicinal species 1 laden polymer is spray-coated orotherwise deposited onto the Primary Dressing Surface. Following that,mask/mold cavity 1 is placed against the freshly deposited polymer andUV illumination is used to cure the polymer through the mask/mold cavitythereby cross-linking only those open regions in the mask/mold cavity.In those regions that did not see any UV light, the polymer has not beencross-linked and is easily removed in a subsequent developer and/orsolvent rinse. A pattern of medicinal species 1 infused PolymerProtuberances (those that correspond to the openings in mask/mold cavity1) are fabricated in this way.

In an identical manner, medicinal specie 2 laden polymer is fashionedinto a different pattern of medicinal species 2 infused PolymerProtuberances (those that correspond to the openings in mask/mold cavity2) and likewise for species 3, 4, 5 and mask/mold cavities 3, 4, 5respectively. In this way, the Primary Dressing Surface can be comprisedof numerous and different medicinal specie infused PolymerProtuberances.

In one embodiment, the medicinal species laden polymer is PGSA and thespecies is silver nanoparticles.

In one embodiment, the medicinal species laden polymer is PGSA and thespecies is zinc nanoparticles.

In one embodiment, the mask/mold cavities are comprised of a quartz(i.e. uv-transparent) mask with a relief structure etched into thesurface and a thin chrome layer everywhere the quartz has not beenetched. The chrome layer would have openings in it to allow the passageof uv light. In those regions where the chrome layer blocks the uv lightfrom passing through, the PGSA remains uncured and easily removed. Afterexposure, we soak the dressing fabric in developer and/or solvent whichdissolves away only those regions of PGSA that have not been exposed.The regions that have been exposed (i.e. cross-linked) become insolublein the developer solution and remain on the Primary Dressing Surface asan array of Polymer Protuberances.

In one embodiment, the Polymer Protuberances would be circular in crosssection with a tapered conical shape.

In still yet another preferred method of fabrication Reactive IonEtching (RIE) methods are used to pattern the polymer layers that havebeen deposited onto the Primary Dressing Surface. By way of example,PLGA1 polymer is formed by mixing medicinal species 1 nanoparticles andPLGA into a solvent and magnetically stirring. And likewise, PLGA2polymer is formed by mixing medicinal specie 2 nanoparticles and PLGAinto a solvent and magnetically stirring, etc.

Following this, PLGA1, PLGA2, PLGA3 layers of medicinal specie infusedpolymer layers are sprayed or otherwise deposited onto the PrimaryDressing Surface (there could be more than 3). In this example, thePrimary Dressing Surface is already flat and receptive to micro/nanofabrication. After Soft baking (to drive out the solvents and form asolid multi-layer stack), an Aluminum hard mask layer issputter-deposited across polymer stack.

Following this, a layer of photoresist is spun-coated, sprayed-on orotherwise deposited onto the Aluminum layer and soft baked.

Following this, the photoresist is patterned using a mask and ContactAligner and/or Stepper Lithography Tool. After exposure, the photoresistis developed and only those regions that were exposed are developed away(in the case of positive-tone photoresist). After development, a wetAluminum Etchant is used to remove the Aluminum hardmask only in thoseregions were the positive-tone photoresist was exposed therebytransferring the pattern in the mask to the Aluminum layer.

After Aluminum Etch, CF4 and/or O2 Reactive Ion Etch (RIE) is used toetch down through the medicinal species containing polymer layers (usingthe Aluminum as a masking layer). When the RIE is completed, theremaining Aluminum mask is etched away and the pattern of PolymerProtuberances remain.

Medical Dressings include gauze, films, gels, foams, hydrocolloids,alginates, hydrogels, polysaccharide pastes granules and beads, amongother things.

Occlusive dressings are made from substances that are impervious tomoisture such as plastic or latex.

Hydrocolloid Dressings are typically biodegradable, non-breathable andadheres to the skin without any additional adhesion mechanism (tape orother). Typically, hydrocolloid dressings have an active dressingsurface comprised of a cross-linked adhesive containing gelatin, pectin,carboxy-methylcellulose and any number of other polymers that absorbwater and swell, thereby forming a moist, soft, gel over the woundsurface that promotes healing.

Of significant importance to the galvanic action of “pushing” metallicions into the wound bed via electrochemical forces (and achieving theanti-microbial response produced thereby) is the need for anelectrically conductive electrolyte medium. This electrolyte istypically found within the wound exudate itself. However, wound exudatecan sometimes dry up, thereby reducing the galvanic action considerably.When this happens, it may be necessary to periodically refresh the woundexudate by applying a saline rinse. The adhesive tabs on theNano-Enhanced Wound Dressing are engineered to allow a fresh stream ofsaline solution to pass between the wound bed and the primary dressingsurface, thereby reinvigorating the galvanic action.

In one embodiment, the medicinal species would be incorporated into thePolymer Protuberances as entombed nanoparticles that are released whenthe protuberances dissolve away. However, sometimes the medicinalspecies might be in the form of a coating that is deposited overtop ofthe Polymer Protuberances.

In one possible embodiment, the Polymer Protuberances are coated orotherwise containing a wax (paraffin) like substance that only allowsthe release of entombed medicinals in response to the human bodytemperature (98.6 degrees Fahrenheit).

In another possible embodiment, the Polymer Protuberances are activated(i.e. they release their medicinal constituents) as a result of somestimulus. For example, there could be: activation by a saline rinse,activation by sweat or perspiration, activation by body temperature,activation by wound exudate and/or activation by magnetic or electricmeans.

Depending on the use and type of wound to be treated, the medicinalnanoparticles may be uniformly distributed within the polymerprotuberances. In an alternative embodiment, the medicinal nanoparticlesmay be non-uniformly distributed within the polymer protuberances so asto facilitate a non-uniform release of anti-microbial and/or anti-bioticagents.

The speed with which the nanoparticles are released into the wound is afunction of the polymer protuberances, including the material itself,the concentration of nanoparticles contained therein, the size of theprotuberances, and shape of the protuberances. For example, highermolecular weight polymers dissolve more slowly than lower molecularweight polymers. Therefore, a wound healing system intended to treat awound slowly over a long period of time may comprise a higher molecularweight polymer than a wound healing system intended to treat a woundover a shorter period of time.

In certain embodiments, it is desirable to release multiple medicines atdifferent times with different rates to from an optimal wound treatmentsystem. In this case, a medicine that is desirably introduced first intoa wound, such as pain killer, can be contained in a low molecular weightpolymer. Subsequent medicines that are to be introduced into a wound ina desired order can then be contained in increasingly higher molecularweight polymers. In this way, a single wound healing system provides theability to tune the release rate of medicinal nanoparticles veryspecifically.

In addition, the size and shape of the polymer protuberances will affectthe release characteristics of the nanoparticles contained therein. Forinstance, larger diameter protuberances will take longer to controllablyrelease their entombed dose of nanoparticles (aka nanomedicinals) thansmaller diameter protuberances. And, if the protuberances should take onthe shape of a tapered cone, the smaller end will dissolve more quicklythan the larger base.

With regard to a non-uniform distribution of nanoparticles in thepolymer protuberances, such an embodiment provides much flexibility inthe release rate of nanomedicinals into the wound. For example,micropillars can be comprised of many separate layers of PGSA, with eachhaving a different volume (or weight) fraction of nanoparticles. Bymaking micropillars that have such a gradient of nanoparticles from thetip to the base, one can alter the release rate of nanomedicinals intothe wound. In one embodiment, a greater concentration of medicinalnanoparticles can be initially introduced into a wound, and taper offthe amount over time by forming micropillars with more nanoparticles inthe tip and less in the base. The opposite is also true, e.g., ramp upthe amount of medicine that is introduce into a wound via nanoparticlesby forming micropillars with less nanoparticles in the tip and more inthe base.

Preferably, but not necessarily, materials to be used for the adhesivestrip include vinyl, latex and/or combinations thereof.

In one embodiment according to the present disclosure, numerous PGSAmicropillars with nanoparticles contained therein arephotolithographically fashioned onto a conductive, perforated PLGAprimary Dressing surface. This is represented in FIGS. 8A-8R, which aredescribed in more detail below.

Starting with a 100 mm diameter, 525 μm thick, Single-Side Polished(SSP), 1-0-0 crystalline Silicon wafer, a layer of Photoresist is spincoated on the top surface, as shown in FIG. 8A.

Mask 1 is positioned against the photoresist and exposed withultraviolet (UV) light using a Contact Aligner, as shown in FIG. 8B.Because the resist is positive tone, exposure to UV light causesscission of the long chain polymer molecules in the resist therebymaking it more soluble in developer solution (as compared to thoseregions that are not exposed). Openings (i.e. transparent regions) inMask1 allow UV light to pass through the mask to illuminate the resistbeneath. Opaque regions of the mask (shown in black, in FIG. 8B) do notallow light to pass.

After (through the mask) exposure and development, the resist is clearedout in those regions where it had been exposed, as shown in FIG. 8C.And, in those regions where it had not been exposed, the resist remainson the surface of the Silicon Wafer. Processing of the resist in thisway (the so-called lithographic process) allows the pattern in Mask1(the Primary Dressing dimensions and geometry) to transfer into theresist layer.

FIG. 8D illustrates the Silicon Wafer after Deep Reactive Ion Etching(DRIE) using an SF6/C4F8 Bosch Etch Process to a nominal depth of 100 μminto the surface.

FIG. 8E shows the same cross section as FIG. 8D, except the remainingresist mask has been removed using an oxygen (O2) plasma treatmentand/or hot solvent bath. FIG. 8E illustrates the Mold Cavity for thePrimary Dressing. The Lateral Extent of the Primary Dressing isdetermined by the geometric details in Mask1. The Thickness of thePrimary Dressing is determined by the DRIE etch depth. In oneembodiment, the Primary Dressing will have dimensions of 20 mm×15 mm×100μm thick.

In FIG. 8F, a conformal, Sacrificial Release Layer (500 nm of Copper orOther) has been blanket deposited across the wafer. This SacrificialRelease Layer coats the bottom, sidewalls and top of the wafer andallows for the Primary Dressing to be Lifted Off at a later step.

In FIG. 8G, the mold cavity is coarsely filled with Polymer 1, whichcomprises a viscous mixture of suspended nanoparticles and dissolvedpolymer granules in a solvent. In one embodiment, Silver Nanoparticles(5 nm-10 nm-20 nm diameter) will be suspended in a viscous mixture ofPLGA (Poly-lactic-co-glycolic acid) granules dissolved in solvent. Theviscous liquid will be poured, troweled or otherwise deposited into theMold Cavity.

In FIG. 8H, a separately-prepared PDMS pad is pressed against thenanoparticle-laden PLGA under appropriate conditions of Pressure andTemperature to cause the PLGA/Nanoparticle mixture to reflow and fillall of the little nooks and crannies of the Mold Cavity. The Mold Cavityfor the Primary Dressing has many hundreds (or thousands) of Silicon“Posts” that the PLGA/Nanoparticles must flow around once the volume ofthe Mold Cavity is completely filled. In FIG. 8H, there are only twoSilicon Posts shown and they are each conformally coated with theSacrificial Release Layer. These Posts correspond to opaque regions inthe original Mask1. When the Primary Dressing is released from the MoldCavity, in the location of the each and every Silicon Post will be athrough hole within which wound effluent can pass. The number, size,shape and spacing of the numerous Silicon Posts in the Mold Cavity willhelp to determine how fast liquids can pass through the PrimaryDressing. They will also help to determine the wettability of thePrimary Dressing surface.

FIG. 8I shows the nanoparticle-laden PLGA over-filling the Mold Cavityafter removal of the PDMS pad.

In FIG. 8J, Chemical Mechanical Polishing (CMP) is used to “planarize”the surface of the wafer (i.e. remove any portions of polymer that stickout, above the surface of the wafer). Ideally, a flat surface isavailable to work with in the subsequent processing steps.

In FIG. 8K, the wafer is coated with a nanoparticle-laden, UV-curablePolymer 2. In one embodiment, Silver (Zinc, Gold or Other) nanoparticleswill be mixed with PGSA (Poly-glycerol-co-sebacate) polymer to form aviscous, nanoparticle-laden liquid that is spun on or sprayed across thewafer.

In FIG. 8L, Mask 2 is placed against the baked Polymer 2 film andexposed with UV light. Polymer 2 (nanoparticle-laden PGSA) is UV curableso that ultraviolet light causes the polymer to cross-link therebyreducing its solubility in developer.

After development, only those regions of Polymer 2 that have beenexposed with UV light remain, as shown in FIG. 8M. FIG. 8M shows anarray of Polymer 2 micropillars affixed to the top surface of thePrimary Dressing. Tentative dimensions for the micropillars will be 5 μmdiameter and 10 μm tall.

In Figures FIG. 8N-8P, the same set of steps as in FIG. 8K-8M areperformed. FIG. 8N shows a new nanoparticle-laden Polymer 3 depositedacross the wafer. Polymer 2 and Polymer 3 may or may not be the samebase polymers, but they will have different nanoparticles containedtherein. Polymer 3 is spun on or sprayed on and more or less disregardsthe existing set of Polymer 2 micropillars.

After deposition of Polymer 3, Mask 3 is placed in contact with it andUV illumination causes the polymer to cross-link in those areas of themask that are open as shown in FIG. 8O. The openings in Mask 2 aredifferent from the openings in Mask 3.

After development, in FIG. 8P, Polymer 2 and Polymer 3 micropillarsremain across the surface of the Primary Dressing. Repeating thisprocess (Deposit Nanoparticle-Laden Polymer, Expose, Develop AwayNon-Exposed Regions, etc) any number of times would allow numerousmicropillars to be fashioned across the surface of the Primary Dressing.

After processing the micropillars, the Primary Dressing must be releasedfrom the Silicon Wafer. Throughout this whole process, the Silicon Waferhas been a temporary “positioning vehicle” for holding the PrimaryDressing Surface and positioning the micropillars relative to eachother. The Alignment Marks required for mask registration were etchedinto the Silicon wafer at the onset. Otherwise, it would be impossibleto precisely position one family of micropillars relative to another.This gives considerable positional freedom of micropillar ensemble 1versus micropillar ensemble 2 versus micropillar ensemble N.

And, part of the development process will include changes in geometry,size, shape, spacing, etc of these micropillars which is only possiblebecause there is a stable “platform” (i.e. the Silicon Wafer) from whichto work. In the end, the whole wafer is immersed in Copper Etchant andthe Sacrificial Release Layer is eaten away as shown in FIG. 8Q.

Once the Sacrificial Release Layer is etched away, there is no inherentadhesion between the Primary Dressing (with all of its micropillars) andthe underlying Silicon Wafer so the dressing lifts off. Once harvestedfrom the sacrificial etchant and rinsed in DI Water, the PrimaryDressing is readied for subsequent attachment to the Secondary Dressing,as shown in FIG. 8R.

After attachment to the Secondary Dressing, a water impermeable AdhesiveStrip is fashioned to hold the Primary/Secondary Dressing against thewound area in the same manner as a conventional Band-Aid.

In one embodiment, the Secondary Dressing is woven from a material thatmay include: cotton, wool, polyester, nylon, rayon, silk and/orcombinations of same.

In one embodiment, the size (diameter, height) and spacing (aka pitch)of the micropillars, including the geometrical pattern that they makewhen integrated onto the Primary Dressing surface is chosen so as togenerate an electrochemical (i.e., galvanic) charge that is comparableto or greater than the natural charge produced by the skin duringhealing in the absence of the dressing.

FIGS. 9A-9F show various patterns and arrays of perforations and pillarsthat can be used according to different embodiments. For example, FIG.9A shows a Primary Dressing Surface with FIG. 9B showing a close-up(without micropillars) of hexagonal, circular or other perforations usedfor moisture management and compliance).

FIG. 9C shows iso(sceles)-hexagonal arrays of micropillars, while FIG.9D depicts concentric circular arrays of 10 μm diameter micropillars. Inthis figure, black micropillars represent silver nano-particles, andgrey micropillars represent zinc nano-particles.

Multiple instances of the iso-hexagonal micropillars on the PrimaryDressing Surface are shown in FIG. 9E, and concentric circularmicropillars on the Primary Dressing Surface are shown in FIG. 9F. Inthese figures, black micropillars represent silver nano-particles, greymicropillars represent zinc nano-particles, and white represents theperforation/thru-holes.

In one embodiment, there is disclosed a three-dimensional method oftreating a wound, by using the enhanced wound care system describedherein. The method comprises covering the wound with a primary dressingsurface as disclosed herein, e.g., one comprising biocompatible and/orbiodegradable polymer protuberances that are inserted into the wound tomake direct contact with the wound.

PROPHETIC EXAMPLES

The disclosure described herein is not meant to be limited in scope bythe specific prophetic examples disclosed. These prophetic examples areintended to be illustrative of the disclosure only and not whollyencompassing of it.

Prophetic Example 1

A Nano-Enhanced Wound Dressing according to the present disclosure maycomprise a pattern of tapered PLGA micropillars on a perforated,conductive polymer Primary Dressing Surface. In this embodiment, eachtapered micropillar may have a Base Diameter of 10 μm with a Height of20 μm and a Spacing of 20 μm. In addition, each tapered micropillar mayfurther comprise two different polymer layers, the first layer (nearestto the skin) containing a uniform distribution of 10 nm Silvernanoparticles and the second layer (furthest from the skin) containing auniform distribution of 10 nm Zinc nanoparticles.

The micropillars may be fabricated using a rolling, thermo-compressionor stamp, hot embossing technique wherein a mold master is temporarilypushed against the multiple PLGA layers under suitable conditions ofpressure, temperature and time in order to cause the PLGA material toreflow and fill the conical depressions in said mold. Upon release thereshall be tapered, dissolvable, nanoparticle-containing, polymerprotuberances that, when brought into contact with the wound exudate,will exhibit an enhanced galvanic response with anti-microbialproperties. And, as the PLGA micropillars dissolve away, additionalsilver and zinc will be controllably released into the wound.

Prophetic Example 2

A Nano-Enhanced Wound Dressing according to the present disclosure mayalso comprise a Woven Primary Dressing Surface onto which 5 mm HexagonIslands of PEDOT are hot embossed. In this embodiment, each HexagonIsland further comprises multiple patterns of micropillars, with eachseparate pattern of micropillars further comprising PGSA polymer thatcontains a different medicinal specie nanoparticle. In this example,there are three possible different medicinal species of nanoparticles.The first is silver (10 nm), the second is Zinc (10 nm) and the third isGold (10 nm). As the biodegradable PGSA dissolves away, three medicinalspecies will be released into the wound bed for enhanced and sustainedanti-microbial action.

Prophetic Example 3

A Nano-Enhanced Wound Dressing according to the present disclosure mayalso comprise a molded PLGA Primary Dressing Surface onto which PGSAmicropillars can be fashioned using photo-lithographic processes. Inthis embodiment, the PLGA primary dressing is made electricallyconductive by virtue of the Silver nanoparticles immersed therein. Thismay be done when the molten PLGA material is pressed into the mold. Alsofound within the primary dressing surface of this embodiment, arethru-holes which allow moisture to pass. PGSA, abiodegradable/biocompatible/photosensitive polymer with Silver and/orZinc nanoparticles immersed therein may be spun onto the primarydressing surface and illuminated with UV light through a contact mask.The mask contains tiny openings in the chrome where the location ofpillars are desired. UV light passes through the mask and cures the PGSAin these locations only, whereas the unexposed PGSA may be dissolvedaway in subsequent development steps. Second and third rounds ofspinning, exposing and developing cause secondary and tertiarymicropillars to be formed with secondary and tertiary medicinalnano-particles held therein.

Claimed Embodiments from Priority U.S. Provisional 61/956,479

The following 32 embodiments were claimed in the U.S. provisionalapplication 61/956,479 which is incorporated herein by reference in itsentirety for all purposes.

One aspect provides an enhanced wound-healing system comprised of one ormore layers juxtaposed between a primary dressing surface and an outercover wherein said primary dressing surface is further comprised ofbiocompatible and/or biodegradable polymer protuberances formedthereupon wherein each of said polymer protuberances is furthercomprised of medicinal nanoparticles infused therein and/or thereupon.

In one embodiment, the polymer protuberances are in the shape of apillar with a base having dimensions on the order of 1 um to 100 um.

In one embodiment, the polymer protuberances have a cross-section shapethat is: round, square, rectangular, hexagonal, elliptical or completelygeneral.

In one embodiment, the medicinal nanoparticles infused within thepolymer protuberances are selected from: silver, gold, copper, zinc,platinum, palladium and/or combinations thereof.

In one embodiment, the medicinal nanoparticles infused within thepolymer protuberances are selected so as to facilitate galvanic actionbetween said protuberances and the wound electrolyte.

In one embodiment, the medicinal nanoparticles are uniformly distributedwithin the polymer protuberances.

In one embodiment, the medicinal nanoparticles are non-uniformlydistributed within the polymer protuberances so as to facilitate theoptimal controlled release of anti-microbial and/or anti-biotic agents.

In one embodiment, the size, shape and spacing of the polymerprotuberances are selected to maximize the contact area between saidprotuberances (i.e. electrodes) and the wound electrolyte for optimalgalvanic response.

In one embodiment, the biodegradable polymer is selected from: PLA, PGA,PEG, PLGA and/or PGSA.

In one embodiment, the biocompatible polymer is comprised of PEDOT.

In one embodiment, the medicinal nanoparticles are spherical in shapewith a diameter on the order of 5 nm to 100 nm.

In one embodiment, polymer protuberances devoid of any medicinalnanoparticles are instead coated with a medicinal layer.

In one embodiment, the medicinal nanoparticles are chosen to optimizethe dissolution rate of different medicinal substances throughout thehealing cycle.

In one embodiment, the primary dressing surface is a woven fabric.

In one embodiment, the polymer protuberances make the primary dressingsurface superhydrophobic.

In one embodiment, the primary dressing surface is comprised of aperforated polymer.

In one embodiment, the primary dressing surface is comprised ofperforated mylar, polyethylene, polypropylene, nylon, rayon and/orcombinations thereof.

In one embodiment, the medicinal nanoparticles include anti-microbial,anti-fungal and/or anti-biotic agents.

In one embodiment, the medicinal nanoparticles are coated withanti-agglomeration agents.

In one embodiment, the polymer protuberances are activated (i.e. theirmedicinal constituents are released) as a result of some stimulus.

In one embodiment, one of more activation steps is carried out:activation by a saline rinse, activation by body temperature, activationby sweat or perspiration, activation by wound exudate and/or activationby magnetic means.

In one embodiment, a method of fabricating multiple-specie polymerprotuberances on a primary dressing surface is provided whereby

-   -   a first medicinal nanoparticle infused polymer layer is        deposited onto the primary dressing surface    -   a second medicinal nanoparticle infused polymer layer is        deposited overtop of the first polymer layer    -   a third medicinal nanoparticles infused polymer layer is        deposited overtop of the second polymer layer    -   a heated mold with a complementary pattern of pits is pressed        against the primary dressing surface and the intervening        multiple polymer layers to form a pattern of multiple-specie        polymer protuberances.

In one embodiment, the first medicinal nanoparticle infused polymerlayer is comprised of zinc nanoparticles in PLGA.

In one embodiment, the second medicinal nanoparticle infused polymerlayer is comprised of silver nanoparticles in PLGA.

In one embodiment, the mold is made from silicon and includes anon-stick layer.

In one embodiment, the polymer protuberances are in the shape of atapered cone.

In one embodiment, a method of fabricating single-specie polymerprotuberances on a primary dressing surface is provided whereby

-   -   a first medicinal nanoparticle infused polymer layer is        deposited onto the primary dressing surface and uv light        exposure through a first mask is done followed by development        (removal) of the unexposed regions thereby resulting in a first        pattern of single-specie polymer protuberances    -   a second medicinal nanoparticle infused polymer layer is        deposited onto the primary dressing surface and uv light        exposure through a second mask is done followed by development        (removal) of the unexposed regions thereby resulting in a second        pattern of single-specie polymer protuberances different from        the previous.    -   a third medicinal nanoparticle infused polymer layer is        deposited onto the primary dressing surface and uv light        exposure through a third mask is done followed by development        (removal) of the unexposed regions thereby resulting in a third        pattern of single-specie polymer protuberances different from        the previous.

In one embodiment, the biodegradable polymer is PGSA.

In one embodiment, the polymer protuberances are spaced apart on s scalethat is compatible with the natural extracellular matrix.

In one embodiment, the first medicinal nanoparticle is silver.

In one embodiment, the second medicinal nanoparticle is zinc.

In one embodiment, the third medicinal nanoparticle is selected from anynumber of anti-microbial, anti-fungal, anti-biotic, germicidal and/oranti-bacterial agents.

In sum, the preferred embodiments and examples disclosed in theforegoing specification are used therein as vehicles of description, andnot of limitation. There is no intention, in the use of such embodimentsand examples to exclude any equivalents of the features shown anddescribed, or portions thereof. It is appreciated that numerousmodifications and/or embellishments to these embodiments and examplesmay be devised by those who are skilled in the art.

Therefore, it is understood that all such modifications and/orembellishments which fall within the spirit and scope of the presentdisclosure shall be covered by the following enumerated claims.

What is claimed is:
 1. An enhanced wound care system comprising: aprimary dressing surface with numerous electrically conductive polymerprotuberances fashioned thereupon; wherein the electrically conductivepolymer protuberances are comprised of biocompatible and/orbiodegradable polymer with numerous metallic nanoparticles embeddedtherein; wherein the metallic nanoparticles are comprised of two or moreelectrochemically distinct metals; wherein the primary dressing surfaceis designed to electrically connect said numerous electricallyconductive polymer protuberances into geometrical patterns across thewound bed; wherein the numerous electrically conductive polymerprotuberances, when immersed into a wound exudate with electrolyticfunctionality, will establish a galvanic cell response for purposes ofelectrical stimulation, to accelerate the wound healing process.
 2. Theenhanced wound care system of claim 1, wherein the polymer protuberanceshave a columnar or pillar shape with a base having a longest dimensionranging from 1 μm to 1000 μm, and a cross-section shape that is round,square, rectangular, hexagonal, elliptical, completely general, orcombinations thereof.
 3. The enhanced wound care system of claim 1,wherein the metallic nanoparticles comprise nanoparticles of potassium.sodium, barium, calcium, manganese, chromium, cadmium, iron, nickel,tin, lead, antimony, bismuth, arsenic, mercury, silver, gold, copper,zinc, platinum, palladium, magnesium, aluminum, and/or combinationsthereof.
 4. The enhanced wound care system of claim 1, wherein themetallic nanoparticles are uniformly distributed within the polymerprotuberances.
 5. The enhanced wound care system of claim 1, wherein themetallic nanoparticles are non-uniformly distributed within the polymerprotuberances.
 6. The enhanced wound care system of claim 5, wherein themetallic nanoparticles have a varying concentration from the tip of thepolymer protuberances to the base of the polymer protuberances.
 7. Theenhanced wound care system of claim 1, wherein the polymer protuberancesfurther comprise anti-microbial, anti-fungal, anti-biotic, painreduction, and/or growth-promoting agents.
 8. The enhanced wound caresystem of claim 7, wherein growth-promoting agents are present andcomprise Interleukins (IL-6, IL-7, IL-8), Keratinocyte growth factor(KGF) and/or Hepatocyte growth factor (HGF).
 9. The enhanced wound caresystem of claim 1, wherein the metallic nanoparticles are spherical inshape with a diameter ranging from 2 nm to 500 nm.
 10. The enhancedwound care system of claim 1, wherein the biodegradable polymer ispresent and comprises PLA, PGA, PEG, PLGA, PGSA, and/or combinationsthereof.
 11. The enhanced wound care system of claim 1, wherein thebiocompatible polymer is present and comprised of PEDOT.
 12. Theenhanced wound care system of claim 1, wherein the molecular weight ofthe polymer in the polymer protuberances is chosen to optimize thecontrolled release rate of metallic nanoparticles into the wound. 13.The enhanced wound care system of claim 1, wherein the spacing and sizeof the polymer protuberances are selected so as to make the primarydressing surface Superhydrophobic.
 14. The enhanced wound care system ofclaim 1, wherein the enhanced wound care system further comprises anouter cover and at least one layer located between the primary dressingand the outer cover.
 15. The enhanced wound care system of claim 14,wherein the outer cover is comprised of a polymer, chosen from latex,mylar, polyethylene, polypropylene, nylon, rayon and/or combinationsthereof.
 16. The enhanced wound care system of claim 1, wherein thepolymer protuberances release the metallic nanoparticles as a result ofa stimulus.
 17. The enhanced wound care system of claim 16, wherein saidstimulus comprises a saline rinse, a change in temperature, sweat orperspiration, wound electrolytes, an electrical field, a magnetic field,or any combination of the foregoing.
 18. A method of making a enhancedwound care system of claim 1 comprising: dispersing the metallicnanoparticles in the at least one biocompatible and/or biodegradablepolymer; and depositing said metallic nanoparticle containing polymeronto a primary dressing surface to form the three-dimensional polymerprotuberances.
 19. The method of claim 18, further comprising placingone or more secondary layers over the primary dressing on the sideopposite the three-dimensional polymer protuberances.
 20. The method ofclaim 19, further comprising placing an outer layer on top of the one ormore secondary layers, such that the one or more secondary layers arelocated between the primary dressing and the outer layer.
 21. The methodof claim 18, wherein the polymer protuberances comprisemultiple-species, and are formed by a method comprising: depositing afirst polymer layer containing metallic nanoparticles onto the primarydressing surface; depositing a second polymer layer containing metallicnanoparticles overtop of the first polymer layer; depositing a thirdpolymer layer containing medicinal nanoparticles overtop of the secondpolymer layer; and pressing a heated mold cavity with a complementarypattern of pits against the primary dressing surface and the first,second, and third polymer layers to form a pattern of multiple-speciepolymer protuberances.
 22. The method of claim 21, wherein the firstpolymer layer comprises zinc nanoparticles in PLGA; the second polymerlayer comprises silver nanoparticles in PLGA; and the third polymerlayer comprises as medicinal nanoparticles anti-microbial agents,anti-fungal agents, anti-biotic agents, germicidal agents,anti-bacterial agents, growth-promoting agents, pain reduction agents,and/or combinations thereof.
 23. The method of claim 21, wherein themold is made from silicon and includes a non-stick layer.
 24. The methodof claim 18, wherein the polymer protuberances are in the shape of atapered cone.
 25. The method of claim 18, wherein the polymerprotuberances are formed by a method comprising: depositing a firstpolymer layer containing metallic nanoparticles onto the primarydressing surface; placing a mask over top of and proximal to the firstpolymer layer, wherein said mask has a pattern with openings to allowlight to pass there-through; exposing the first polymer layer to UVlight to cure the polymer in the mask openings only, leaving the areasnot exposed to UV light uncured; removing the uncured areas of the firstpolymer layer thereby forming a first pattern of polymer protuberances;depositing a second polymer layer containing metallic nanoparticles ontothe primary dressing surface; placing a mask over top of and proximal tothe second polymer layer, wherein said mask has a pattern with openingsto allow light to pass there-through; exposing the second polymer layerto UV light to cure the polymer in the mask openings only, leaving theareas not exposed to UV light uncured; removing the uncured areas of thesecond polymer layer thereby forming a second pattern of polymerprotuberances different from the first pattern; depositing a thirdpolymer layer containing medicinal nanoparticles onto the primarydressing surface; placing a mask over top of and proximal to the thirdpolymer layer, wherein said mask has a pattern with openings to allowlight to pass there-through; exposing the third polymer layer to UVlight to cure the polymer in the mask openings only, leaving the areasnot exposed to UV light uncured; removing the uncured areas of the thirdpolymer layer thereby forming a third pattern of polymer protuberancesdifferent from both the first pattern and the second pattern.
 26. Themethod of claim 25, wherein at least one of the first, second, or thirdpolymer comprises PGSA.
 27. The method of claim 25, wherein the firstmetallic nanoparticle comprises silver; the second metallic nanoparticlecomprises zinc; and the third medicinal nanoparticle is selected fromanti-microbial agents, anti-fungal agents, anti-biotic agents,germicidal and/or anti-bacterial agents, pain reducing agents, and/orcombinations thereof.
 28. A three-dimensional method of treating awound, said method comprising: inserting the enhanced wound care systemof claim 1 into a wound, wherein said polymer protuberances make directcontact with the wound exudate with electrolytic functionality.
 29. Themethod of claim 28, wherein the biocompatible and/or biodegradablepolymer dissolves in the wound and thereby releases said metallicnanoparticles into the wound.
 30. The method of claim 28, wherein themetallic nanoparticles comprise potassium, sodium, barium, calcium,manganese, chromium, cadmium, iron, nickel, tin, lead, antimony,bismuth, arsenic, mercury, silver, gold, copper, zinc, platinum,palladium, magnesium, aluminum, and combinations thereof.
 31. The methodof claim 28, wherein the biodegradable polymer if present is selectedfrom: PLA, PGA, PEG, PLGA and/or PGSA; and the biocompatible polymer ifpresent is comprised of PEDOT.
 32. The enhanced wound care system ofclaim 1, wherein each of the polymer protuberances comprises only onespecie of the metallic nanoparticles made of electrochemically distinctmetals.